Secured Steel Reinforcing Bar (&#34;Rebar&#34;) Safety Cap

ABSTRACT

A safety cap for steel reinforcing bar (“rebar”) has an outer body with an enlarged cap and an elongated stem extending from the cap. A hole in the stem enables the safety cap to fit over the exposed end of a section of rebar. A metal insert, molded within the safety cap, prevents the rebar from punching through the safety cap if a worker were to fall onto the safety cap. The safety cap is retained on the end of the rebar so that it cannot be easily knocked off, by a pair of threaded set screws, or by a magnet positioned within the safety cap over the end of the rebar.

CROSS REFERENCE TO RELATED APPLICATIONS

This United States non-provisional patent application claims priority to U.S. provisional patent application Ser. 62/486,627, filed Apr. 18, 2017, for all purposes. The disclosure of that provisional patent application is incorporated herein by reference, to the extent not inconsistent with this disclosure.

BACKGROUND Field of the Invention

This invention relates to apparatus used in connection with various industrial settings, in particular (but not exclusively) the construction trade. With more particularity, the present invention relates to apparatus for covering exposed ends of steel reinforcing bar, commonly known as “rebar,” used in connection with concrete work.

As is well known in the relevant field, steel rebar is used to reinforce poured concrete structures, such as floors and walls. Frequently, the rebar is positioned within a form, and wet concrete is poured into the form, thus embedding the rebar.

It is common that at certain stages of construction, one or both ends of a piece of rebar will protrude from the concrete. Rebar is typically a round-in-cross section steel bar, by way of example ⅜″ or ½″ in diameter. It is readily appreciated that should a worker fall onto an exposed rebar end, grave injury or death could occur.

In an effort to reduce the injurious effect of such a fall, pieces known as “rebar safety caps,” referred to at times herein as “safety caps,” are known. While different embodiments exist, commonly the commercially available rebar caps have an outer body in a shape similar to a mushroom, when viewed from one side. An elongated stem has a hole therein to receive a rebar end. Some prior art rebar safety caps have flexible fins within the hole, which are bent back by the rebar end when the safety cap is put in place; the intent of the fins is to hold the rebar safety cap in place by virtue of a friction fit, the fins tending to permit some variation in the rebar diameter, etc.

However, in practice the prior art rebar safety caps, particularly those with the finned mounting holes, do not reliably stay affixed to the rebar end and tend to fall off of their own accord or are easily dislodged. As can be readily understood, the unsafe situation resumes should any rebar end be exposed.

The known prior art rebar safety caps share a common issue with maintaining the caps in place on the ends of the rebar.

SUMMARY OF THE INVENTION

The secured rebar safety cap embodying the principles of the present invention comprises an outer body, which may be made of molded plastic or similar materials, having an enlarged cap and an elongated stem attached to the cap. The stem comprises a hole suitably sized to fit over the end of a section of rebar, for example 2″ long. A steel (or other metal, or similar strong material) insert or reinforcing plate is preferably embedded in the plastic at the upper end of the hole, to prevent the rebar from punching through the plastic safety cap. In a first embodiment of the secured rebar safety cap, one or more, typically two, set screws are threadably positioned in holes in the stem and may be tightened against the rebar to secure it in place. In a second embodiment, one or more magnets disposed in or proximal the stem hole, for example at the end of the stem hole, secure the safety cap in place when placed on the end of the rebar. It is to be understood that the magnetic force of the magnets in attraction to the steel/metal/ferrous material of the rebar holds the safety cap in place.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a first embodiment (set screw secured) of a secured rebar safety cap embodying the principles of the present invention.

FIG. 2 is a side view in cross section of the first embodiment shown in FIG. 1.

FIG. 3 is a side view of a second embodiment (magnet secured) of a secured rebar safety cap embodying the principles of the present invention.

FIG. 4 is a side view in cross section of the second embodiment shown in FIG. 3.

DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENT(S)

While various secured rebar safety caps can embody the principles of the present invention, with reference to the drawings some of the presently preferred embodiments can be described.

A First Embodiment

Referring to FIGS. 1 and 2, FIG. 1 is an external side view of a first embodiment of a secured rebar safety cap 10 embodying the principles of the present invention. A plastic (or similar material) outer body 20 comprises an elongated collar or stem 30 and an enlarged cap 40. Stem 30 has a hole 32 to receive the end of a rebar. As can be readily understood, enlarged cap 40 provides a greatly increased contact area, should someone fall onto secured rebar safety cap 10. A section of rebar 50 is shown; it is understood that the end of rebar 50 terminates in and is covered by secured rebar safety cap 10. Preferably, safety cap 10 is made of a plastic or similar material, for example molded by an injection molding process or similar process. It is to be understood that other materials may be used as well.

FIG. 2 is a cross section of the secured rebar safety cap 10 of FIG. 1. An insert 60, typically of metal formed by stamping, etc., is typically molded into plastic outer body 20. Insert 60 provides greatly increased strength and resistance to the end of rebar 50 puncturing or punching through the end of plastic outer body 20, in the event of someone falling onto the safety cap.

A key aspect of secured safety cap 10 is a means for securing same to the rebar end, in this embodiment comprising one or more, typically two, set screws 70 which may be inserted through and threadably disposed in threaded holes in plastic outer body 20, for example stem 30, or some other part of safety cap 10. As can be readily understood by known set screws in other settings, set screws 70 may be advanced by turning them and tightening them against rebar 50. Once tightened (by hand, a screwdriver, a wrench, etc. as appropriate), set screws 70 hold rebar safety cap 10 securely in place, yet can be loosened and rebar safety cap 10 removed and re-used.

A Second Embodiment

FIG. 3 is an external side view of a second embodiment of a secured rebar safety cap 100 embodying the principles of the present invention. Similar to the first embodiment, a plastic outer body 120 comprises an elongated collar or stem 130 and an enlarged cap 140. Stem 130 has a hole 132 to receive the end of a rebar. As can be readily understood, enlarged cap 140 provides a greatly increased contact area, should someone fall onto secured rebar safety cap 100. A section of rebar 150 is shown; it is understood that the end of rebar 150 terminates in and is covered by secured safety cap 100.

FIG. 4 is a cross section of the secured rebar safety cap 100 of FIG. 3. As with the first embodiment, an insert 160, typically of metal formed by stamping, etc., is typically molded into plastic outer body 120. Insert 160 provides greatly increased strength and resistance to the end of rebar 150 puncturing the end of plastic outer body 120, in the event of someone falling onto the safety cap.

A key aspect of this embodiment of secured safety cap 100 is a means for securing same to the rebar end, in this embodiment comprising one or more magnets within the body of the rebar cap, in FIG. 4 shown as magnet 170. In view of the steel (ferrous) material from which the rebar is made, magnet 170 is attracted to rebar 150, holding safety cap 100 securely in place. It is understood that the magnetic securing force can be overcome by a user, so that safety cap 100 may be simply pulled off of a rebar, then slid down onto another rebar, where the magnet will hold it in place. It is understood that while FIG. 4 shows magnet 170 positioned over the end of rebar 150, magnet 170 could be positioned wholly or partially around rebar 150, for example in the shape of a collar. Magnet 170 may be in various shapes and positions, as long as it is sufficiently close to rebar 150 to attract and hold safety cap 100 in place on rebar 150.

CONCLUSION

While the preceding description contains many specificities, it is to be understood that same are presented only to describe some of the presently preferred embodiments of the invention, and not by way of limitation. Changes can be made to various aspects of the invention, without departing from the scope thereof. For example, dimensions may be varied to suit different rebar sizes; different materials may be used; the rebar safety cap may be used to cover any exposed piece, whether rebar, steel stakes, wooden stakes for the set screw embodiment, etc.

Therefore, the scope of the invention is to be determined not by the illustrative examples set forth above, but by the appended claims and their legal equivalents. 

I claim:
 1. A safety cap for placement over the exposed end of steel reinforcing bar, comprising: an outer body comprising an enlarged cap and an elongated stem attached thereto and extending therefrom, said stem comprising a longitudinal hole therein to receive an end of a steel reinforcing bar; and a means for releasably securing said safety cap to said steel reinforcing bar.
 2. The safety cap of claim 1, wherein said means for releasably securing said safety cap to said steel reinforcing bar comprises one or more set screws threadably disposed through said stem and into said longitudinal hole, whereby advancing said set screws against said steel reinforcing bar secures said safety cap to said reinforcing bar.
 3. The safety cap of claim 2, further comprising an insert positioned over an uppermost end of said hole in said stem, preventing said end of said reinforcing bar from punching through said cap.
 4. The safety cap of claim 3, wherein said insert comprises a metal plate.
 5. The safety cap of claim 1, wherein said safety cap is made of a molded plastic.
 6. The safety cap of claim 5, wherein said means for releasably securing said safety cap to said steel reinforcing bar comprises one or more set screws threadably disposed through said stem and into said longitudinal hole, whereby advancing said set screws against said steel reinforcing bar secures said safety cap to said reinforcing bar.
 7. The safety cap of claim 6, further comprising an insert positioned over an uppermost end of said hole in said stem, preventing said end of said reinforcing bar from punching through said cap.
 8. The safety cap of claim 7, whereby said insert is metal and is molded into said safety cap.
 9. The safety cap of claim 1, wherein said means for releasably securing said safety cap to said steel reinforcing bar comprises a magnet disposed in said cap, and positioned proximal said reinforcing bar when said reinforcing bar is inserted into said longitudinal hole in said stem, such that said magnet holds said safety cap in place on said reinforcing bar.
 10. The safety cap of claim 9, further comprising an insert positioned over an uppermost end of said hole in said stem, preventing said end of said reinforcing bar from punching through said cap.
 11. The safety cap of claim 10, wherein said insert comprises a metal plate.
 12. The safety cap of claim 9, wherein said safety cap is formed from molded plastic.
 13. The safety cap of claim 12, wherein said magnet and said metal plate are molded into said safety cap.
 14. A safety cap for releasable attachment over the exposed end of steel reinforcing bar, comprising: an outer body comprising an enlarged cap and an elongated stem attached thereto and extending therefrom, said stem comprising a longitudinal hole therein to receive an end of a steel reinforcing bar, said safety cap formed from molded plastic; a metal plate molded into said safety cap positioned over an uppermost end of said hole in said stem, preventing said end of said reinforcing bar from punching through said cap; and a means for releasably securing said safety cap to said steel reinforcing bar.
 15. The safety cap of claim 14, wherein said means for releasably securing said safety cap to said steel reinforcing bar comprises one or more set screws threadably disposed through said stem and into said longitudinal hole, whereby advancing said set screws against said steel reinforcing bar secures said safety cap to said reinforcing bar.
 16. The safety cap of claim 14, wherein said means for releasably securing said safety cap to said steel reinforcing bar comprises a magnet disposed in said cap, and positioned proximal said reinforcing bar when said reinforcing bar is inserted into said longitudinal hole in said stem, such that said magnet holds said safety cap in place on said reinforcing bar. 